WHEEL ASSEMBLY AND METHOD FOR MAKING SAME

Abstract

The present invention provides an apparatus and a method for manufacturing a wheel hub to reduce lateral run-out. Specifically, the present invention provides an apparatus and a method for machining the inner and outer surfaces of the wheel hub after the wheel bolts and bearing have been attached to the wheel hub. A grind wheel is used to finish an inner flange portion and outer flange portion of the wheel hub.

Claims

1.-20. (canceled)

21. An apparatus for preparing a flange surface of a wheel hub in combination with the wheel hub, the apparatus comprising: i) a first component mounting the wheel hub and for rotating the wheel hub about a first axis of rotation, the wheel hub having first and second flange portions with first and second flange surfaces, respectively; and ii) a second component including a grind wheel, wherein the second component rotates the grind wheel about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation enclose an acute angle; wherein the grind wheel includes an inner lip and an outer lip including first and second grind surfaces, respectively, for grinding the first and second flange portions, the first and second grind surfaces both being perpendicular to the first axis of rotation, the inner and outer lip defining a channel therebetween, the channel receiving the wheel bolts of the wheel hub when the first and second grind surfaces finish the first and second flange surfaces on the wheel hub.

22. The apparatus of claim 21, wherein said grind wheel is constructed of boron.

23. The apparatus of claim 21, wherein the wheel hub is mounted on a bearing.

24. The apparatus of claim 21, wherein the first and second lips are inner and outer lips, respectively.

25. The apparatus of claim 21, wherein the grind wheel is a singular structure unitarily formed to include the inner and outer lips.

26. The apparatus of claim 21, wherein the first and second lips are parallel to one another and both extend in a direction askew to both of the first and second axes.

27. The apparatus of claim 24, wherein the inner and outer lips are frustoconical in shape.

28. An apparatus for preparing a flange surface of a wheel hub in combination with the wheel hub, the apparatus comprising: i) a first component mounting the wheel hub, the wheel hub having a plurality of wheel bolts and having a first flange portion and a second flange portion with first and second flange surfaces, respectively, wherein the first component rotates the wheel hub in a first axis of rotation and the first and second flange portions are perpendicular to the first axis of rotation, and the first flange portion is located interior to a cylindrical region defined by a portion of the wheel bolts closest to the first axis of rotation; and ii) a second component including a milling tool, wherein the second component rotates the milling tool about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation are fixed, parallel and sufficiently offset so that the milling tool mills the first and second flange portions; wherein the milling tool has first and second ground surfaces generally perpendicular to the first axis of rotation for finishing the first and second flange surfaces, respectively, and further includes first and second lips, defining a channel therebetween, the channel receiving the wheel bolts of the wheel hub when the first and second grind surfaces finish the first and second flange surfaces of the wheel hub.

29. The apparatus of claim 28, wherein the wheel hub is mounted to a bearing.

30. The apparatus of claim 28, wherein the first and second lips are inner and outer lips, respectively.

31. The apparatus of claim 28, wherein the milling tool is a singular structure unitarily formed to include the first and second lips.

32. The apparatus of claim 28, wherein the first and second lips are parallel to one another and both extend in a direction askew to both of the first and second axes.

33. The apparatus of claim 30, wherein the inner and outer lips are frustoconical in shape.

34. An apparatus for preparing surfaces of a wheel hub in combination with the wheel hub, the wheel hub including first and second flange portions including first and second flange surfaces, respectively, the first and second flange surfaces being circular, the wheel hub further including a plurality of wheel bolts radially positioned between the first and second flange surfaces, comprising: i) a first component for mounting a wheel hub wherein the first component rotates the wheel hub in a first axis of rotation and the first and second flange surfaces are perpendicular to the first axis of rotation; and ii) a second component including a milling tool, wherein the second component rotates the milling tool about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation are fixed, parallel and sufficiently offset so that the milling tool mills the first and second flange portions; wherein the milling tool has first and second grind surfaces generally perpendicular to the first axis of rotation for finishing the first and second flange surfaces, respectively, the milling tool defining a channel receiving the wheel bolts of the wheel hub when the first and second grind surfaces finish the first and second flange surfaces of the wheel hub.

35. The apparatus of claim 33, wherein the milling tool is a singular structure unitarily formed to include first and second lips defining the channel.

36. The apparatus of claim 34, wherein the channel is radially defined between the first and second lips.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Objects and advantages together with the operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:

[0012] FIG. 1 is a perspective view of a portion of a wheel hub assembly engaged with a mill cutter.

[0013] FIG. 2 is a perspective view of a wheel hub assembly including a knuckle.

[0014] FIG. 3 is a perspective view of a portion of a wheel hub assembly engaged with a mill cutter.

[0015] FIG. 4 is a perspective view of a portion of a wheel hub assembly engaged with a grind wheel.

[0016] FIG. 5 is a perspective view of a portion of a wheel hub assembly engaged with a grind wheel.

[0017] FIG. 6 is a cross-sectional view of a portion of a wheel hub assembly engaged with a grind wheel.

DETAILED DESCRIPTION OF THE INVENTION

[0018] FIGS. 1 and 2 illustrate a wheel hub assembly 1. The assembly 1 may include a variety of components, including a wheel hub 4, bearing 5, and knuckle 16. The wheel hub 4 may have a flange face 12 and a pilot portion 6. The pilot portion 6 extends generally outward from the flange face 12 so as to allow a rotor to be guided and affixed to the wheel hub assembly as known to one of ordinary skill in the art.

[0019] The knuckle 16 may have a generally circular bore 18 formed therein and a plurality of outwardly extending appendages or legs 20 that are capable of attachment to the vehicle through a plurality of apertures formed in the plurality of legs 20, as is known in the art.

[0020] The bearing 5 may be press-fit into the bore 18 of the knuckle 16. However, it should be understood that a variety of different knuckle/bearing attachment configurations may be utilized. For example, the bearing 5 may be press-fit with or without a snap ring, or may be held in place with a nut, or secured by other methods known in the art. Alternatively, a portion of the bearing 5 may be bolted to the knuckle 16 or integrally formed with the knuckle 16. Moreover, an inner portion of the bearing 5 may be integrally formed with the wheel hub.

[0021] A plurality of respective wheel bolts 3 may be attachable to the wheel hub 4. In an embodiment, the wheel bolts 3 are attached to the flange face 12 in a predetermined pattern, such as equidistantly spaced, and on the same pitch circle diameter. The wheel bolts 3 are oriented with the threaded ends extending outwardly so as to connect a rotor and an associated wheel onto the wheel hub 4 as commonly known in the skill of the art. The flange face 12 may have a relief channel 8 machined therein. The relief channel 8 may divide the flange face 12 into an outer flange surface 7 and an inner flange surface 9. In an embodiment, the relief channel 8 is turned into the flange face 12 so that the plurality of the wheel bolts 3 are positioned in the relief channel 8.

[0022] The wheel hub 4 may be positioned on the bearing 5. The bearing 5 is not limited to being positioned as illustrated in the figures and may, for example, secure about and/or attach about the inside diameter of the wheel hub 4, the outside diameter of the wheel hub 4 and/or therebetween. The bearing 5 may be any bearing type as known to one of ordinary skill in the art, including but not limited to a single row, a double row, a ball, a roller and/or the like. The bearing 5 may be integrated with the wheel hub 4. In an embodiment, the bearing 5 is used in the final wheel assembly 1 such that the bearing 5 is not detached from and/or reassembled with the wheel hub 4. To this end, the bearing 5 is used in the wheel assembly 1 that is attachable and/or securable to and/or secured to, for example, a vehicle.

[0023] Removal of the bearing 5 after machining the flange face 12 may cause lateral run-out of the wheel hub 4. Advantageously, the present invention provides an apparatus and a method for machining the flange face 12 after the bearing 5 is attached to and/or integrated with the wheel hub 4. The wheel hub 4 may be secured to the bearing 5 so that the wheel hub 4 can rotate with respect to the bearing 5. Alternatively, the wheel hub 4 and bearing 5 may rotate with respect to the knuckle 16. The wheel hub 4 may be affixed or mounted onto the bearing 5 in a variety of wheel hub/bearing configurations as known to one of ordinary skill in the art.

[0024] In operation, the wheel hub assembly 1 is machined to flatten the outer flange surface 7 and the inner flange surface 9 that will contact a rotor, and thus minimize any lateral run-out. The machining process flattens the inner flange surface 9 and the outer flange surface 7 such that surfaces 7, 9 are parallel with respect to each other. In an embodiment, the machining process finishes the flange surfaces 7, 9 such that the flange surfaces 7, 9 are co-planar. As is further discussed below, either the mill cutting process or alternatively, the use of grind wheel process accomplishes the machining of the flange face 12. Both processes, however, may occur after the wheel bolts 3 and/or the bearing 5 are attached or secured to the wheel hub 4.

[0025] FIGS. 3 and 5 illustrate rotational directions for certain components of the wheel hub assembly and components used for the finishing thereof. It will be appreciated that the rotational direction of each component is not limited to the direction of rotation illustrated. Rather, each denoted components may rotate in any direction as required.

[0026] FIG. 3 illustrates a milling process for the flange face 12 and wheel hub assembly 1. The wheel hub 4 is situated on the bearing 5, allowing the wheel hub 4 to rotate about an axis determined by the bearing 5. The wheel hub 4 is positioned on the bearing 5 so as to allow the flange face 12 to engage an inner mill cutter 2 and an outer mill cutter 10 protruding from a machine, such as a lathe. In one embodiment, the inner mill cutter 2 and the outer mill cutter 10 are stationary and each consists of a cutting end, but individually rotate about an axis determined by the tool and it's bearing. The cutting end of the inner mill cutter 2 engages the inner flange surface 9 of the flange face 12. The cutting end of the outer mill cutter 10 engages the outer flange surface 7 of the flange face 12. Alternatively, one of the mill cutters 2, 10 may be used to machine the inner flange surface 9 and/or the outer flange surface 7.

[0027] The milling process may occur as the wheel hub 4 rotates on the bearing 5 in a clockwise motion. In a preferred embodiment, the mill cutters 2, 10 move from a storage position and engage the flange surfaces 7, 9 as described above. The outer mill cutter 10 and/or the inner mill cutter 2 moves radially in and out as the hub wheel 4 turns, milling and finishing the flange surfaces 7, 9. This process of finishing reduces lateral run-out.

[0028] As shown FIG. 4-6, an alternate embodiment for refinishing the flange face 12 is a grinding process. The grinding process involves use of a grind wheel 11. The grind wheel 11 may be constructed from an abrasive material that may be, for example, boron, diamond, or any other abrasive and immalleable material known to one of ordinary skill of the art. In an embodiment, the grind wheel 11 is a singular cylindrical apparatus that may consist of an inner lip 13 and an outer lip 14. In one embodiment, the inner lip 13 has a shape that corresponds with the inner flange surface 9. Similarly, in an embodiment, the outer lip 14 and the outer flange surface 7 have corresponding shapes. Located in between the inner lip 13 and outer lip 14 is a channel 15. The channel 15 and the relief channel 8 also have corresponding shapes. As described below, the purpose of the channel 15 is to allow the wheel bolts 3 of the wheel hub 4 to pass or clear within the grind wheel 11 while the grind wheel 11 engages and finishes the flange surfaces 7, 9. While the grind wheel 11 is described as having both an inner lip and outer lip, it will be appreciated that other configurations may be used. For example, the grind wheel 11 may comprise a single lip configured to engage either the outer flange surface 7 or the inner flange surface 9.

[0029] The grind wheel 11 serves as a machining apparatus for the purpose of finishing the flange face 12. Referencing FIG. 6, the open face of grind wheel 11 is placed on the top of the wheel hub 4 so that the grind wheel 11 engages flange face 12. The inner lip 13 is aligned along the inner flange surface 9. The outer lip 14 is aligned along the outer flange surface 7. This arrangement allows the outer lip 14 to cup the wheel bolts 3 so that the wheel bolts 3 terminate within the channel 15 of the grind wheel 11.

[0030] FIGS. 5 and 6 illustrate the grinding process of the present invention. The grind wheel 11 is placed on top of the wheel hub 4 as described above. As the wheel hub 4 rotates in a clockwise direction about the axis of the bearing 5, the grind wheel 11 is rotated in the counterclockwise direction. The rotations of the wheel hub 4 and the grind wheel 11 are not limited to clockwise and counterclockwise rotations respectively, but, preferably are in opposite directions as known to one of ordinary skill of the art. The inner flange surface 9 and outer flange surface 7 are finished by the friction created against the inner lip 13 and outer lip 14 of the grind wheel. In an embodiment, the grind wheel 11 rotates at a higher rate of speed than the wheel hub 11 and in an opposite direction with respect to the wheel hub 11. The engagement of the grind wheel 11 upon the flange surfaces 7, 9 causes a high degree of friction that removes material from the flange surfaces 7, 9 and creates the flattening and finishing process of the flange face 12, thereby reducing lateral run-out.

[0031] Other objects and features of the present invention will become apparent when reviewed in light of detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims